US6269898B1ExpiredUtility

Unitary power module for electric bicycles, bicycle combinations and vehicles

Assignee: CURRIE TECH INCPriority: Feb 23, 1998Filed: Apr 30, 1999Granted: Aug 7, 2001

Est. expiryFeb 23, 2018(expired)· nominal 20-yr term from priority

Inventors:Richard A. Mayer Bruce S. Widmann Seth A. Terr Devin S. Bank Malcolm R. Currie

B62M 6/65B62M 6/60

PatentIndex Score

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References

Claims

Abstract

A wheeled vehicle comprises a frame having a steerable front wheel having an axle affixed to a front portion of said frame, and a hub rear wheel having an axle affixed to a rear portion of said frame. A unitary power module is used as a propulsion system, which includes a target sprocket and a mounting frame, with the target sprocket comprising a disk shaped assembly having an center opening to allow the unitary member to be placed about the wheel axle. The target sprocket mates to the hub (or axle) of either of the wheels to enable target sprocket to be concentrically attached to the wheel by engagement with the wheel by securing elements. The mounting frame may be aligned with and rotatably attached to the target sprocket to allow for aligned rotation of the target sprocket about the wheel axle. The mounting frame may be attached to the unitary member by a bearing or the like and has an opening to receive an electric motor having a pinion sprocket to enable the pinion sprocket to engage the target sprocket to rotate the rear wheel upon application by the rider of propulsion controls. A free wheel clutch may be provided on the unitary power module or target sprocket to allow the wheel to rotate faster than the motor without motor drag.

Claims

exact text as granted — not AI-modified

We claim:

1. A unitary power module for rotating a wheel of a wheeled vehicle comprising:
a target sprocket defining a generally disk shaped member having a center opening to allow said target sprocket to be placed about a wheel axle of said wheel with said wheel axle supported on the frame of the vehicle, said target sprocket having a target coupler engagable to the wheel to enable said target sprocket to be substantially concentrically attached to said wheel upon engagement with said target coupler to said wheel; and
a mounting frame securable to the frame and rotatably attached to said target sprocket to allow for aligned independent-rotation of said target sprocket on said mounting frame, said mounting frame disposed to receive an electric motor enabling a pinion sprocket affixed on said electric motor to propel said target sprocket and rotate said wheel, said mounting frame providing a single point of reference for aligning said pinion sprocket with said target sprocket.

2. The invention of claim 1 additionally including an electric motor having a pinion sprocket affixed to said mounting frame.

3. The invention of claim 1 wherein the target sprocket includes a hollow collar, which attaches to said mounting frame by a bearing.

4. The invention of claim 3 wherein said hollow collar includes a free wheel clutch positioned proximate to said target sprocket.

5. The invention of claim 1 wherein a free wheel clutch is affixed to a shaft upon which said pinion gear is mounted and said pinion sprocket is positioned adjacent to and engages said free wheel clutch.

6. The invention of claim 1 wherein said target coupler is integral with said target sprocket and is disposed to be affixed to a flange of a hub of a wheel.

7. The invention of claims 1 , 4 , or 5 wherein said target coupler is affixed to a wheel hub of said wheel by an engaging member.

8. The invention of claim 7 wherein said target coupler engaging member includes a threaded pattern, which engages a matching threaded, formed proximate to said wheel hub.

9. The invention of claim 1 wherein said target sprocket mates a hub of a bicycle wheel.

10. The invention of claim 1 wherein said target sprocket and pinion sprocket each has a plurality of teeth suitable to be engaged by a drive chain.

11. The invention of claim 1 wherein said target sprocket and pinion sprocket each has a plurality of gear teeth suitable to be engaged by one another.

12. The invention of claim 1 wherein said target sprocket and pinion sprocket each has a surface suitable to be engaged by a drive belt.

13. An unitary power module kit for converting a standard bicycle having a frame and front and rear wheels, each having a hub with an axle, to an electric powered bicycle comprising:
a member comprising a target sprocket and a mounting frame, said target sprocket comprising a disk shaped assembly having an center opening to allow said member to be placed about the axle, said target sprocket having a target coupler engagable with one of said wheels of said bicycle to enable said target sprocket to be substantially concentrically attached to said wheel by engagement with the wheel by securing elements; and
said mounting frame rotatably attached to said target sprocket to allow for aligned independent rotation of said target sprocket on said mounting frame, said mounting frame having an element suitable to receive an electric motor to enable a pinion sprocket affixed on said electric motor to propel said target sprocket and rotate said bicycle wheel, said mounting frame providing a single point of reference for aligning said pinion sprocket with said target sprocket.

14. The invention of claim 13 additionally including an electric motor having a pinion sprocket disposed connected to said mounting frame.

15. The invention of claim 14 wherein a battery suitable to power said electric motor is disposed on said bicycle to connect to an electrical connector.

16. The invention of claim 13 additionally including an electric motor having a pinion sprocket affixed to said mounting frame, said electric motor connected to a battery by a connector and connected to an electrical control to regulate the speed of the electrical motor.

17. The invention of claim 13 wherein the target sprocket includes a hollow collar, which attaches to said mounting frame by a bearing.

18. The invention of claim 17 wherein said hollow collar includes a free wheel clutch positioned proximate to said target sprocket.

19. The invention of claim 13 wherein a free wheel clutch is affixed to a shaft upon which said pinion is mounted and said pinion sprocket is positioned adjacent to and engages said free wheel clutch.

20. The invention of claim 13 wherein said target coupler is integral with said target sprocket and is disposed to be affixed to a flange of a hub of a bicycle wheel.

21. The invention of claims 13 or 19 wherein said target coupler is integral with said target sprocket which includes a groove pattern disposed to mate a woven spoke pattern of the wheel.

22. The invention of claim 13 wherein said target coupler includes a groove pattern disposed to mate a woven spoke pattern of the bicycle wheel.

23. The invention of claim 13 wherein said target sprocket mates a hub of a bicycle wheel.

24. The invention of claim 13 wherein said target sprocket and pinion sprocket each has a plurality of teeth suitable to be engaged by a drive chain.

25. The invention of claim 13 wherein said target sprocket and pinion sprocket each has a plurality of gear teeth suitable to be engaged by one another.

26. The invention of claim 13 wherein said target sprocket and pinion sprocket each has a surface suitable to be engaged by a drive belt.

27. An electric vehicle comprising
a frame having at least one wheel with an axle and hub affixed to a portion of the frame, the frame adapted to receive a battery, a connector suitable to connect the battery and the motor, and a controller suitable to control the speed of an electric motor;
a unitary power module comprising:
a unitary member comprising a target sprocket and a mounting frame, said target sprocket comprising a disk shaped assembly having an center opening to allow said unitary member to be placed about the axle, said target sprocket having a target coupler engaging the wheel of said vehicle to enable said target sprocket to be substantially concentrically attached to said rear wheel by outside engagement with said wheel hub; and
said mounting frame rotatably attached to said target sprocket by a bearing for aligned independent rotation between said mounting frame and said target sprocket, said mounting frame having an element to receive an electric motor, said electric motor having a pinion sprocket disposed to engage said target sprocket to rotate said wheel upon application by a rider of the controller, said mounting frame securable to said frame, said mounting frame providing a single point of reference for aligning said pinion sprocket with said target sprocket.

28. An electric vehicle comprising
a frame having propulsion controls positioned thereon;
a steerable front wheel having an axle affixed to a front portion of said frame;
a rear wheel having an axle affixed to a rear portion of said frame;
a unitary power module comprising:
an electric motor having a pinion sprocket affixed thereon, said electric motor suitable to be connected to a battery by a battery cable and to a controller to regulate motor speed via said propulsion controls;
a unitary member comprising a target sprocket and a mounting frame, said target sprocket comprising a disk shaped assembly having an center opening to allow said target sprocket to be placed about one of said axles, said target sprocket having a target coupler engaging a wheel of said vehicle to enable said target sprocket to be substantially concentrically attached to said wheel by outside engagement with the wheel hub; and
said mounting frame rotatably attached to said target sprocket by a bearing for aligned independent rotation between said mounting frame and target sprocket, said mounting frame having an element to receive said electric motor to enable said pinion sprocket to engage said target sprocket to rotate said wheel upon application by the rider of propulsion controls, said mounting frame secured to a fixed portion of said vehicle, said mounting frame providing a single point of reference for aligning said pinion sprocket with said target sprocket.

29. The invention of claim 27 or 28 additionally including an electric motor having a pinion sprocket disposed to connected to said mounting frame, said electric motor suitable to be connected to a battery by an electrical connector.

30. The invention of claim 27 or 28 wherein a battery suitable to power said electric motor is disposed to be connected to an electrical connector.

31. The invention of claim 27 or 28 additionally including an electric motor having a pinion sprocket affixed to said mounting kame, said electric motor connected to a battery by a connector and connected to the controller to regulate the speed of the electrical motor.

32. The invention of claim 27 or 28 wherein the target sprocket includes a hollow collar, which attaches to said mounting frame by a bearing.

33. The invention of claim 27 or 28 wherein said hollow collar includes a free wheel clutch positioned adjacent proximate to said target sprocket.

34. The invention of claim 27 or 28 wherein a free wheel clutch is affixed to a shaft upon which said pinion gear is mounted and said pinion sprocket is positioned adjacent to and engages said free wheel clutch.

35. The invention of claim 27 or 28 wherein said target coupler is integral with said target sprocket and is disposed to be affixed to a flange of a hub of a vehicle wheel.

36. The invention of claim 27 or 28 wherein said target coupler is integral with said target sprocket includes a groove pattern disposed to mate a woven spoke pattern of the wheel.

37. The invention of claim 27 or 28 additionally including free wheel clutch connected to the motor shaft upon which said pinion gear is mounted, said pinion sprocket positioned adjacent t 6 and engaging said free wheel clutch, and said target coupler is integral with said target sprocket includes a groove pattern disposed to mate a woven spoke pattern of the wheel.

38. The invention of claim 27 or 28 wherein said target coupler includes a groove pattern disposed to mate a woven spoke pattern of the bicycle wheel.

39. The invention of claims 27 or 28 wherein said target sprocket mates a disk shaped bicycle wheel.

40. The invention of claim 27 or 28 wherein said target sprocket and pinion sprocket each have a plurality of teeth engaged by a drive chain.

41. The invention of claims 27 or 28 wherein said target sprocket and pinion sprocket each have a plurality of gear teeth suitable to be engaged by one another.

42. The invention of claims 27 or 28 wherein said target sprocket and pinion sprocket each have a surface suitable to be engaged by a drive belt.

43. A unitary power module for mounting a propulsion system on a vehicle having at least two wheels comprising:
a target sprocket defining a disk shaped member having a center opening to allow said sprocket to be placed about a wheel axle of said vehicle, said target sprocket having a target coupler engagable to mate a wheel of said vehicle to enable said sprocket to be substantially concentrically attached to said wheel by engagement with said wheel by securing elements, and
a mounting frame rotatably attached to said target sprocket to allow for independent rotation of said target sprocket about said wheel axle prior to mating of said target sprocket to said wheel, said mounting frame having an element to receive an electric motor to enable a pinion sprocket affixed on said motor to engage a second sprocket mounted on a second shaft positioned on said mounting frame, said second shaft having a third sprocket mounted thereon, said second sprocket substantially aligned with and engaging said pinion sprocket and said third sprocket substantially aligned with and engaging said target sprocket to propel said target sprocket upon rotation of said pinion sprocket and rotate said vehicle wheel, said mounting frame secured to a fixed portion of said vehicle and providing a single point of reference for aligning said pinion sprocket with said second sprocket and said third sprocket with said target sprocket.

44. A propulsion system kit for converting a standard bicycle having a frame and rear hub wheel having an axle to an electric bicycle comprising:
an electric motor having a pinion sprocket gear affixed thereon, said electric motor suitable to be connected to said battery by a battery cable;
a unitary power module for mounting a propulsion system on a bicycle comprising:
a target sprocket defining a disk shaped member having a center opening to allow said sprocket to be placed about a wheel axle of said bicycle, said target sprocket having a target coupler mating a wheel hub of a wheel of said bicycle to enable said sprocket to be substantially concentrically attached to said wheel hub by engagement with securing elements; and
a mounting frame rotatably attached to said target sprocket to allow for aligned independent rotation of said target sprocket about said wheel axle prior to mating of said target sprocket to said wheel, said mounting frame having an element to receive an electric motor to enable a pinion sprocket affixed on said motor to engage a second sprocket positioned thereon by a second shaft, said second sprocket shaft having a third sprocket suitable for engagement with said target sprocket to propel said target sprocket and rotate said bicycle wheel upon rotation of said pinion sprocket via said electric motor, said mounting frame providing a single point of reference for aligning said pinion sprocket with said second sprocket and said target sprocket and said third sprocket.

45. An electric vehicle having at least two wheels comprising
a frame having propulsion controls positioned and thereon;
a steerable front wheel having an axle affixed to a front portion of said frame;
a rear wheel having an axle affixed to a rear portion of said frame;
a propulsion system comprising:
an electric motor having a pinion sprocket affixed thereon, said electric motor suitable to be connected to a battery by a battery cable;
a unitary power module for mounting a propulsion system on said vehicle comprising:
a target sprocket defining a disk shaped member having a center opening to allow said sprocket to be placed about a wheel hub of said wheel, said target sprocket having a target coupler mating a wheel hub of a wheel of said vehicle to enable said sprocket to be substantially concentrically attached to said wheel by engagement with said wheel hub by securing elements; and
a mounting frame rotatably attached to said target sprocket to allow for aligned independent rotation of said target sprocket about said wheel hub prior to mating of said target sprocket to said wheel, said mounting frame having an element to receive an electric motor to enable a pinion sprocket affixed on said motor to engage a second sprocket positioned on a second shaft thereon, said second sprocket shaft having a third sprocket positioned for engagement with said target sprocket to propel said target sprocket and rotate said vehicle wheel upon rotation of said pinion sprocket via said electric motor, said mounting frame providing a single point of reference for aligning said pinion sprocket with said second sprocket and said target sprocket and said third sprocket.

46. The invention of claim 44 or 45 wherein said electric motor is connected to the battery by an electrical cable.

47. The invention of claim 13 , 27 , 28 , 44 or 45 wherein mounting frame element receiving the electric motor is an opening.

48. The invention of claim 44 or 45 wherein said electric motor connected to a battery by a cable and connected to a controller on said vehicle to regulate the speed of the electrical motor.

49. The invention of claim 44 or 45 wherein the target sprocket includes a hollow collar, which attaches to said mounting frame by a bearing.

50. The invention of claim 44 or 45 wherein said hollow collar includes a free wheel clutch positioned proximate to said target sprocket.

51. The invention of claim 44 or 45 wherein a free wheel clutch is affixed to a shaft upon which said pinion gear is mounted and said pinion sprocket is positioned adjacent to and engages said free wheel clutch.

52. The invention of claim 44 or 45 wherein said target coupler is integral with said target sprocket and is disposed to be affixed to a flange of a hub of a bicycle wheel.

53. The invention of claims 44 or 45 wherein said target coupler is integral with said target sprocket includes a groove pattern disposed to mate a woven spoke pattern of the wheel.

54. The invention of claim 44 or 45 additionally including a free wheel clutch connected to the motor shaft upon which said pinion gear is mounted, said pinion sprocket positioned adjacent to and engaging said free wheel clutch, and said target coupler is integral with said target sprocket includes a groove pattern disposed to mate a woven spoke pattern of the wheel.

55. The invention of claim 44 or 45 wherein said target coupler includes a groove pattern disposed to mate a woven spoke pattern of the bicycle wheel.

56. The invention of claim 44 or 45 wherein one plane provides a single point of reference for substantially aligning said pinion sprocket with said second sprocket and second plane provides another point of reference for substantially aligning said third sprocket with said target sprocket.

57. The invention of claim 44 or 45 wherein said target sprocket, said second sprocket, said third sprocket and said pinion sprocket each have a plurality of teeth suitable to be engaged by a drive chain.

58. The invention of claim 43 , 44 or 45 wherein said mounting frame additionally includes a chain connected to said pinion sprocket to rotate said second sprocket, which in turn rotates the third sprocket via the second shaft to engage said target sprocket by a second chain to rotate said target sprocket.

59. The invention of claim 43 , 44 or 45 wherein said pinion sprocket, said second shaft and said target sprocket are positioned to be substantially along a straight line along said mounting frame.

60. The invention of claim 1 , 13 , 27 , 28 , 43 , 44 or 45 wherein said mounting frame additionally includes a second opening suitable to receive a second electric motor having a second pinion sprocket, said pinion sprocket and second pinion sprocket connectable to and aligned so as to each motor is deposed to provide rotational power to said drive module.

61. A target sprocket for an electric vehicle having at least two wheels propulsion system comprising a disk shaped member having an opening to allow a target coupler affixed to said target sprocket to be placed about a vehicle wheel axle, said target sprocket suitable to engage a vehicle wheel hub to enable said sprocket to be concentrically attached to said wheel hub by engagement of securing elements, said target sprocket engagably disposed to be securable to a vehicle wheel and to a mounting frame about a bearing affixed on said mounting frame thereby providing a single point of reference for aligning a pinion sprocket of a motor affixed to said mounting frame with said target sprocket.

62. The invention of claim 61 wherein a free wheel clutch is affixed to said target sprocket.

63. A mounting frame for an electric vehicle propulsion system, said vehicle having at least two wheels, said mounting frame having first and second elements disposed to receive an electric motor having a pinion sprocket, and a target sprocket, respectively, said target sprocket securable to a vehicle wheel hub and securable to said mounting frame about a bearing affixed about one of said elements receiving said target sprocket, said mounting frame providing a single point of reference for aligning said pinion sprocket with said target sprocket.

64. The invention of claim 63 in combination with an electrical motor having a pinion sprocket proximate to said first element, and a target sprocket proximate to said second element.

65. The invention of claim 63 wherein said pinion sprocket is positioned proximate to and engaging a free wheel clutch.

66. The invention of claim 64 wherein said electric motor having a planetary gear positioned between said motor and pinion sprocket.

67. The invention of claim 66 wherein the planetary gear reduces RPM&#39;s of said motor thereby providing reduced RPM&#39;s to said pinion sprocket.

68. An electric powered vehicle comprising:
a frame having at least one wheel with an axle and hub affixed to a portion of the frame, the frame adapted to receive a battery, a connector suitable to connect the battery and the motor, and a controller suitable to control the speed of an electric motor;
a power module comprising:
a target sprocket and a mounting frame, said target sprocket comp g a disk shaped assembly having an center opening to allow said target sprocket to be placed about the axle, said target sprocket having a target coupler engaging the wheel of said vehicle to enable said target sprocket to be substantially concentrically attached to said rear wheel by outside engagement with said wheel, said target coupler affixed to said wheel by an engagement member, and
said mounting frame having an element to receive an electric motor, said electric motor having a pinion sprocket engaging said target sprocket to rotate said wheel upon application by a rider said electric vehicle of the controller, said pinion sprocket aligned with said target sprocket.

69. An electric vehicle having at least two wheels comprising
a frame having propulsion controls positioned thereon;
a steerable front wheel having an axle and hub affixed to a front portion of said frame;
a rear wheel having an axle and hub affixed to a rear portion of said frame;
a power module comprising:
an electric motor having a pinion sprocket affixed thereon, said electric motor connected to a battery by a battery cable and to a controller to regulate motor speed via said propulsion controls;
a target sprocket comprising a disk shaped assembly having a center opening to allow said target sprocket to be placed about one of said axes of one of said wheels, said target sprocket hating a target couplet engaging by outside engagement an engagement member said wheel of said vehicle to enable said target sprocket to be substantially concentrically attached to said wheel; and
a mounting frame having an element to receive said electric motor to enable said pinion sprocket to engage said target sprocket to rotate said wheel upon application by a rider of said electric vehicle propulsion controls, said mounting frame secured to a fixed portion of said vehicle, said mounting frame providing a point of reference for aligning said pinion sprocket with said target sprocket.

70. The invention of claim 68 or 69 wherein said target coupler includes a threaded pattern, which engages a matching threaded, formed proximate to said wheel.

71. The invention of claim 68 or 69 wherein said target sprocket engages the hub of the wheel.

72. The invention of claim 68 or 69 , which said vehicle is selected from the group consisting of mopeds, scooters, and motorcycles; three wheeled vehicles including tricycle-like vehicles; four wheeled vehicles, including wheel chairs, surrey style, golf cart style and delivery style vehicles.

73. The invention of claim 68 or 69 wherein said mounting frame is rotatably attached to said target sprocket.

74. The invention of claim 68 or 69 , wherein said engagement member includes securing elements secured through an extended hub flange on said hub to engage the target coupler.

75. The invention of claim 68 or 69 , wherein said engagement member includes an extended threaded receiving a threaded opening of said target coupler.

76. The invention of claim 68 or 69 , wherein a one-way clutch is mounted between the target sprocket and the hub.

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